CWI Code Book Application Questions and Answers

Question 1

A fabricator has a Welding Procedure Specification (WPS) qualified on 1/2-inch thick plate. According to AWS D1.1, what is the maximum thickness of base metal this WPS is qualified to weld in production?

Accepted Answer

1 inch

Answer

According to AWS D1.1 Table 6.2 (or its current equivalent), a Procedure Qualification Record (PQR) test performed on a 1/2-inch thick plate qualifies the WPS for a maximum production thickness of 2T, where T is the thickness of the test coupon. In this case, 2 * (1/2 inch) = 1 inch.

Question 2

According to the visual inspection acceptance criteria for statically loaded non-tubular connections in AWS D1.1, which of the following describes the allowable limit for undercut on base metal that is 3/4-inch thick?

Accepted Answer

Undercut shall not exceed 1/32 inch.

Answer

AWS D1.1 Table 8.1 (or its current equivalent for visual inspection) states that for material less than 1 inch thick, undercut shall not exceed 1/32 inch (1 mm). An exception allows for deeper undercut up to 1/16 inch for a very short accumulated length, but the general requirement is 1/32 inch.

Question 3

A welder successfully qualifies by performing a CJP groove weld test on a 3/8-inch thick plate in the 3G (vertical-up) position per AWS D1.1. This qualification allows the welder to perform which of the following production welds?

Accepted Answer

Fillet welds in the 1F, 2F, and 3F positions.

Answer

Per AWS D1.1 Table 6.10 (or current equivalent), a welder performance qualification test in the 3G position on plate qualifies the welder for groove welds in the flat (1G), horizontal (2G), and vertical (3G) positions, and for fillet welds in the flat (1F), horizontal (2F), and vertical (3F) positions. It does not qualify for the 4G position. The thickness qualified on a 3/8-inch plate is from 1/8-inch up to 2T (3/4-inch), not unlimited or 1-inch.

Question 4

When applying ASME Section IX, a change to which of the following is considered an essential variable for a Shielded Metal Arc Welding (SMAW) WPS, requiring the procedure to be requalified?

Accepted Answer

A change in the base metal P-Number.

Answer

According to ASME Section IX, QW-250 and QW-403, a change in the P-Number of the base metal is an essential variable for most welding processes, including SMAW. This change is considered to affect the mechanical properties of the weldment and mandates a new Procedure Qualification Record (PQR). Changes in groove design or technique are typically nonessential variables, and a change in brand of electrode within the same AWS classification is not an essential variable.

Question 5

A CWI is monitoring the welding of a 1.5-inch thick steel plate where the qualified WPS, based on AWS D1.1, requires a minimum preheat and interpass temperature of 225°F. What is the correct protocol for measuring this temperature?

Accepted Answer

The temperature must be at or above 225°F in an area approximately 3 inches from the joint, just before initiating an arc.

Answer

AWS D1.1 specifies that preheat and interpass temperatures shall be measured on the base metal at a distance equal to the plate thickness or 3 inches, whichever is less, from the point of welding. The temperature must be checked just prior to initiating the arc for each pass to ensure it is at or above the minimum specified value.

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CWI Code Book Application Questions and Answers